Automated tool change assembly for robotic arm

ABSTRACT

An automated tool change assembly and method for automatically coupling a robotic end effector to a robotic manipulator. The automated tool change assembly of the present invention provides first and second light-weight mechanical joint members for automated coupling to provide a rigid connection that can include an electrical connection to pass power and signals between the end effector and the manipulator. The connection can also have full pass-through mechanical power. The assembly also includes a tool station for docking an end effector. The tool station can also provide a platform to align tools with manipulators in forming the automatic connection between joint members. The tool station also provides a release bar for manually releasing end effectors from manipulators. Software scripts can connect and disconnect the tool change assembly remotely when attached to a robot.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on U.S. Provisional Patent Application No.61/273,880, filed Aug. 10, 2009, on which priority of this patentapplication is based and which is hereby incorporated by reference inits entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

Manipulators on mobile robots require specialized end effectors(tools/components) in order to accomplish particular missions.Currently, deployed systems have end effectors designed, built, andinstalled at the factory. Factory installed tools can only be repairedor replaced in a factory. This limits the effectiveness of the robot tothose missions which can be achieved with a single tool. Heretofore,when a new candidate task is identified, the typical response has beento design and build a new robot intended to perform the specific task.Sometimes existing unmanned ground vehicles (UGV) platforms are used,but just as often, a new robot is created to specifically address thetask. This has resulted in a proliferation of small UGVs, eachperforming admirably on tasks within each of its subset of corecompetencies, but is generally unsuitable for tasks that vary too widelyfrom its essential purpose. It is impractical to expect field teams tocarry multiple UGVs, each suited for a specific task. In addition to thestrain on the physical resources of the field team (e.g., transportationand maintenance), different robots come with different control schemes.This reduces the ability of the operator to capitalize on the experienceand intuition gained from operating previous robots, because theoperator cannot rely on the trained reflexes developed while controllingprevious robots. In fact, these differing control schemes lead tooperator errors and inefficient control.

Another approach has been to design new, more capable robots, but thisapproach has drawbacks because even if a robot were designed and builtto perform all of the tasks currently assigned to UGVs, it would quicklybecome outdated as new tasks and jobs are identified. Additionally,external variables, such as physical environment, make UGVs designed forone environment wholly impractical for use in another environment,meaning a number of new robot types would need to be designed, tested,and built. Systems with replaceable end effectors are also ineffectivebecause they require a technician and possibly a number of specialtytools. Generally, these changes would require a technician to remove thecurrent tool and to attach its replacement. This may involve physicallydisconnecting the tool, disconnecting electrical connections, physicallyattaching the new tool, and hooking up its electrical connections. Thesystem may also require reconfiguring the control software for eachspecialized tool. Particularly, in time critical applications, such asmilitary or civilian Explosives Ordinance Disposal (EOD), this processis too slow and interferes with missions.

Military and law enforcement groups are increasingly relying on UGVs toperform life-threatening tasks ranging from under car inspection to EOD.As small UGVs, such as Omni-Directional Inspection Systems (ODIS), Talonand Packbot have gained acceptance, the variety of tasks they have beenrequired to perform has increased. Drive systems utilize significantpower, unlike industrial robots, these systems are deployed inuncontrolled environments. Driving a system back and forth to physicallydisconnect a tool is impractical. Operators can stand more than 300meters from a site. It can take valuable time and resources to drive arobot away in the course of action.

In addition, it takes a robust design to survive the normal workingenvironment for such devices, both during deployment on the mobile robotand when the manipulator and tools are being stored or transported.Mechanical connections must be compliant to minor variations inmanufacturing tolerances of mating components, or environmentaltolerances which develop when a tool is dropped or bumped againstanother tool in the toolbox, or caused by the presence of debris, suchas dirt and sand, captured from the working environment.

Robotic arms often require specialized configurations to accomplishtheir particular mission, requiring change in the length of a link inthe arm or attaching a different end effector or tool.

Tools that attach to links of the robotic arm that are pivoting orrotating must be able to withstand the large bending movements andtorques that result from this.

An object of the present invention is to provide an automated toolchange assembly for separating robotic end effectors mechanically fromtheir manipulator arms during deployment, thus allowing unhinderedintegration of end effectors as the complexity.

Description of Related Art

SUMMARY OF THE INVENTION

An automated tool change assembly for automatically connecting an endeffector to a robotic arm having a first joint member having a lockingring, an electrical connector, and a connection plate, and a secondjoint member having a cylindrical body, a locking plate, an electricalreceiver, a locking member, and a locking collar, the locking collarbeing coaxially aligned with and slidably coupled to the cylindricalbody by mating with circumferentially spaced axial extending legs of thecylindrical body with a cavity. The cavity is defined by a carrier plateof the locking collar, further including the locking member extendingaxially therefrom, the second joint member including springs between thecollar and the carrier plate and providing force on the locking collaraxially, outward from the body, the locking plate of the second jointmember engaging the locking ring of the first joint member, the lockingplate and the locking ring having at least one interveningcircumferentially spaced tab, which can be engageable in keyedrelationship. The tab can include an engagement hole extending axiallytherethrough. Axially displacing the first joint member into the secondjoint member can position first joint member electrical connectoradjacent electrical receiver. A counter rotation between the first andsecond joint members slides the locking ring tab of first joint memberunder the locking plate tab of second joint member, electricallyconnecting the electrical connector with the electrical receiver andaligning the engagement holes. The spring force on the locking collarcan push the locking pin through the aligned engagement holes of thelocking plate and locking ring connecting the first joint member tosecond joint member.

The assembly of the present invention further includes a follower ring,the follower ring having a tab positioned between the locking plate andthe locking collar carrier plate, preventing movement of the lockingcollar by preventing the locking pin from entering engagement holes, thetab further engaging the locking ring prevents rotation of the lockingring past alignment position and locking ring into alignment with afollower ring of the second joint member.

The locking ring and locking plate further includes a plurality of tabs.A key defined by tabs of the locking ring uniquely engages with anopening formed between two tabs of the lock plate providing only oneengagement orientation of the locking plate with the locking ring.

The assembly can further include a gear motor housed in second jointmember, a mechanically driven tool connected to the first joint memberand a self aligning shaft, wherein the self aligning shaft transfersmechanical power from the gear motor of second joint member to themechanically driven tool of the first joint member.

The self aligning shaft includes a coupler housed in first joint memberhaving a slotted head, a drive shaft having a dowel pin, a compressionspring, and a drive hub housed in the second joint member, the hubhaving a slotted face, a cross slot and a stepped cylindrical bore. Thedrive shaft engages the cylindrical bore, such that the drive hub crossslot provides axial compliance as translational freedom along the axisof the drive shaft is limited by the length of the cross slot when thedowel pin interacts with the cross slot. The compression springpositioned inside the cylindrical bore and coupled to the shaft providesaxial force away outward. Upon rotational alignment, the coupler headengages the drive hub slotted face and the rotational torque istransferred from the drive shaft, through the drive hub to the couplerfor powering the mechanical driven tool.

Mating the dowel pin to the cross slot of the hub can be used to providerotational torque, however, other methods can also be used to passtorque. The engagement of the locking pin with the engagement holes ofthe locking ring and the locking plate locks three translational degreesof freedom and three rotational degrees of freedom. The electricalreceiver includes a pin holder and a pin having a contact surface, theholder for holding the pin in alignment for coupling the electricalreceiver pin contact surface to a contact surface of a pin in a holderof the electrical connector.

The electrical receiver pin contact surface couples to an electricalconnector pin contact surface. A rotary wiping motion as the first jointmember is rotatably connected to the second joint member is formed, therotary wiping motion used for removing debris from the electricalcontact surfaces. The electrical receiver pin comprises a groovedcontact surface, the groove forming multiple contact lines when engagedwith the pin of the electrical connector. The electrical receiverfurther includes a flexible member resting in a notched wall of the pinadjacent the pin holder. The flexible member, an elastomer, can provideaxial force directed toward the center of the electrical receiver, theforce pressing the contact surfaces together during the displacement offirst joint member into second joint member. The flexible member ofelectrical receiver can further provide compliance or resistance tovibration and have a rotation about a connecting member in a bottom ofthe conductor pin.

A tool station can serve for holding first joint member for positioningthe first joint member for automatic engagement or for automaticallydisengaging the first joint member. The tool station further comprisesan engagement member having a body and arms, the arms having analignment ramp, and track, the alignment ramp providing a taperedopening leading to the track for engaging the first joint member.Engagement pins of the first joint member engage the alignment ramp, theramp guiding the engagement pins toward the track such that rotationalfreedom of the first joint member about an axis of the pins providescompliance with height and location parameters of the second jointmember during engagement until further movement of the first jointmember toward the base provides connection of second engagement pins ofthe first joint member with the second alignment ramp, the secondalignment ramp guiding the pins into the track such that the rotationalfreedom of the first joint member is eliminated. A release member havinga lock ramp and a striker plate is coupled to the engagement membercreating an open and close position for release member. The releasemember further including a spring member creating force pushing therelease member to a close position such that a face of the lock rampaligns with the locking collar of the second joint member when engagedwith a first joint member and striker locks the pin of the first jointmember inside the two-stage track. The locking collar provides force onthe face of the release member lock ramp opening the release memberproviding an open two-stage track as the striker is moved. Also includedis a mount member having legs and an attachment member for coupling themount member to a surface, the legs coupled to the engagement member.

The track can be a two-stage track having a first and second alignmentramp or one track, depending on the manipulator's degree of freedom.Second engagement pins can have a shortened length, such that the secondengagement pins are guided by second alignment ramp into second trackadjacent the first track. A lateral guide ramp for guiding lateralmovement of the engagement pins is also included. The tool station canbe mounted to a robot, guided machine, or unmanned vehicle. Theattachment member is rotatably coupled to the surface providingrotational adjustment for aligning the base with the second joint memberduring engagement or the first joint member pins during disengagement.The base engagement member is rotatably coupled to the legs providingtilt adjustment for alignment of the axis of the first joint member tothe axis of the second joint member during engagement.

A manual release lever such that the manual release lever can open thelock ramp of the release member providing a manual operation forreleasing the first joint member. The release member can be actuated bya series of electrically controlled motions of second joint member ormanually. The engagement is created with a rotation of the locking ringinside of the locking plate to provide clearance of notches. The lockingpin further includes a conical surface for mating a chamfered surface onthe teeth of locking ring and plate, wherein rotation forces thechamfered members of locking ring to slide under the chamfered edges oflocking plate teeth, such that the chamfered edges facilitate engagementof the teeth.

The first joint member and the second joint member are engaged to forman electrical connection operative to transmit images, control signals,activators, identification information, video, USB, TCP/IP, UDP, andCanBus, feedback information. The second joint member is connected to arobot arm. A component connected to the first joint member is included.The component can comprises one of an arm linkage, an arm segment, armextender, a gripper, a gimble grip, a flexible joint, a tilt table, adozer, a shovel, a plow, a pan tilt table, a digger, a sensor, adisruptor, a drill, a saw, a cutter, a grinder, a digging tool, or acamera.

A robot end effector automatic-release arrangement comprises a firstjoint member having a locking ring, an electrical connector, and an endeffector connection plate for connecting to a second joint member havinga cylindrical body, a locking plate, an electrical receiver, a lockingpin and a locking collar, the locking collar being coaxially alignedwith and slidably coupled to the cylindrical body by matingcircumferentially spaced axial extending legs of the cylindrical bodywith cavities defined by a carrier plate of the locking collar, thecarrier plate further including the locking pin extending axiallytherefrom, the second joint member including springs between the bodyand the locking collar providing axial force on locking collar outwardfrom the body such that the locking plate of the second joint memberbeing engageable in keyed relationship with the locking ring of thefirst joint member, the locking plate and the locking ring havingintervening circumferentially spaced tabs, the tabs include engagementholes extending axially therethrough, rotatably aligning and displacingthe locking ring into a second joint member providing an electricalreceiver receiving the electrical connector. A counter rotation betweenfirst and second joint members forces the locking ring of first jointmember to slide under and align with the locking plate to connect withthe first joint member and rotates electrical connector forming anelectrical connection with the electrical receiver. The axial force onthe carrier plate of the locking collar pushes the locking pin throughaligned engagement holes of the locking plate and locking ringconnecting the first joint member to second joint member, a robotcomponent attached to the first joint member, and an electroniccomponent in the robot component for receiving an electrical signal froma control unit of the second joint member.

The assembly further comprises a tool station, the tool station forholding the first joint member or positioning the first joint member forautomatic engagement or automatically disengaging the first jointmember. A tool station assembly for automatically connecting of a robotcomponent to a robotic wrist is provided. An engagement member having abody and arms, the arms having a first alignment ramp, a secondalignment ramp, and a two-stage track, the first alignment rampproviding a tapered opening leading to the two-stage track. Lowerengagement pins of a robotic component engage the first alignment rampduring engagement, the ramp guiding the lower pins toward a full lengthinner track of the two-stage track such that rotational freedom of therobotic component about an axis of the pins provides compliance withheight and location parameters of a robotic wrist during engagement.During movement of the lower engagement pins along the full length trackupper engagement pins of the robot component engage the second alignmentramp, the second alignment ramp guiding the upper pins into a shortenedouter track of the two-stage track eliminating the rotational freedom offirst joint member. A release member having a lock ramp and a strikerplate, the release member coupled to the engagement member creating anopen and close position for release member, the release member furtherincluding a spring member creating force pushing the release member to aclose position such that a face of the lock ramp aligns with a lockingcollar of the robotic wrist when engaged with a first joint member andstriker locks the pin of the first joint member inside the two-stagetrack, the locking collar providing force on the face of the releasemember lock ramp such that release member is moved to an open positionproviding an opening on the two-stage track as the striker is moved anda mount member having legs and an attachment member for coupling themount member to a surface, the legs coupled to the engagement member.The tool station can be mounted to a robot, guided machine, or unmannedvehicle.

In addition, provided by the present invention is a method forconnecting a robotic tool to a robotic arm, having the steps of a firstjoint member having a locking ring, an electrical connector, and aconnection plate. A second joint member is provided having a cylindricalbody, a locking plate, an electrical receiver, a locking pin, and alocking collar, the locking collar being coaxially aligned with andslidably coupled to the cylindrical body by mating circumferentiallyspaced axial extending legs of the cylindrical body with cavitiesdefined by a carrier plate of the locking collar, the carrier platefurther including the locking pin extending axially therefrom. Thesecond joint member can include springs between the body and the lockingcollar to provide axial force on the locking collar outward from thebody. Aligning the locking ring of the first joint member in keyedrelationship with the locking plate of the second joint member, thelocking plate and the locking ring have intervening circumferentiallyspaced tabs, the tabs include engagement holes extending axiallytherethrough. Displacing the first joint member into second joint membersuch that the first joint member electrical connector is positionedadjacent electrical receiver, rotating first joint member within secondjoint member to slide the locking ring tabs of first joint member underthe second joint member locking plate tabs, electrically connecting theelectrical connector with the electrical receiver; aligning theengagement holes such that the axial spring force on the locking collarcarrier plate pushes the locking pin through the aligned engagementholes of the locking plate and locking ring connecting the first jointmember to second joint member. Rotating the locking collar, whereby theintervening teeth of the coupler is rotated into engagement with teethlocated circumferentially about the locking collar, wherein the lockingcollar rotation forces the teeth of locking collar to slide over theteeth of coupler. The coupler is clamped into engagement with the firstjoint member; and engaging a retaining pin to lock the collar to thefirst joint member.

The method further includes terminating displacement of the first jointmember into second joint member when the pin engages locking wall.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is a side-perspective view of a tool base assembly and a wristassembly of the automated tool change assembly of the present invention;

FIG. 1b illustrates a robot arm for use with the automated tool changeassembly of the present invention;

FIG. 2a illustrates a side-perspective view of the tool base assembly ofthe automated tool change assembly of the present invention;

FIG. 2b illustrates an exploded view of the tool base assembly shown inFIG. 1;

FIG. 3 illustrates an exploded view of the wrist assembly componentsshown in FIG. 1;

FIG. 4a illustrates a side-perspective view of a lock ring and lockplate of the automated tool change assembly of the present invention;

FIG. 4b illustrates a front view of the lock ring and lock plate of FIG.4a shown in an engaged position;

FIG. 5a illustrates a front view of the tool base assembly displacedinside a wrist assembly of the automated tool change assembly of thepresent invention;

FIG. 5b illustrates a front view showing a lock ring of a tool baseassembly displaced inside a lock plate of a wrist assembly;

FIG. 6 illustrates a front view of the tool base assembly connected to awrist assembly of the automated tool change assembly of the presentinvention;

FIG. 7 illustrates a view of a tool base assembly lock ring and wristassembly lock plate shown in FIG. 6;

FIG. 8 illustrates a top-perspective view of a lock ring and lock plateshown in FIG. 7;

FIG. 9 illustrates a cross-sectional view of the connected wristassembly and tool base assembly shown in FIG. 8;

FIG. 10 illustrates a side-perspective view showing the locking collar,and pins of the automated tool change assembly of the present inventionin an engaged position;

FIG. 11 illustrates a cross-sectional view of the tool base assembly andwrist assembly shown in FIG. 10;

FIG. 12 illustrates a cross-sectional view of a wrist assembly having alock ring ready for engagement of the automated tool change assembly ofthe present invention;

FIG. 13a illustrates a side-perspective view of a lock ring and followerring of the wrist assembly of the automated tool change assembly of thepresent invention;

FIG. 13b illustrates a side-perspective view of a wrist assembly lockingcollar of the automated tool change assembly of the present invention;

FIG. 13c illustrates a cross-sectional view of FIG. 13b alone line A;

FIG. 14a illustrates a lock ring engaging a follower ring of the wristassembly of the automated tool change assembly of the present invention;

FIG. 14b illustrates a cross-sectional view showing the lock ringengaging the follower ring shown in FIG. 14 a;

FIG. 14c illustrates a cross-sectional view of the lock ring shown inFIG. 14b in the connected position;

FIG. 15a illustrates a side-perspective view of a roll pin seated in anelectrical connector of the automated tool change assembly of thepresent invention;

FIG. 15b illustrates a cross-sectional view of the electrical connectorof the wrist assembly of the automated tool change assembly of thepresent invention;

FIG. 16 illustrates a top view of mating conductor pins of the automatedtool change assembly of the present invention;

FIG. 17a illustrates a cross-sectional view of the engaged mechanicalpower take off self-aligning driveshaft of the automated tool changeassembly of the present invention;

FIG. 17b illustrates a coupler preparing to engage a driveshaft of theautomated tool change assembly of the present invention;

FIG. 17c illustrates a side-perspective view showing a coupler driveengaging a driveshaft of the automated tool change assembly of thepresent invention;

FIG. 18 illustrates a side-perspective view of a tool station of theautomated tool change assembly of the present invention;

FIG. 19 illustrates an exploded view of the tool station shown in FIG.18;

FIG. 20 illustrates a view of the tool station shown in FIG. 18connecting to a tool base assembly of the automated tool change assemblyof the present invention;

FIG. 21a illustrates a view illustrating a tool station with a stepthrough of a tool base assembly;

FIG. 21b illustrates a tool station in time sections showing a tool basemechanism of the automated tool change assembly of the presentinvention;

FIG. 21c illustrates a tool station in time sections showing a tool basemechanism of the automated tool change assembly of the presentinvention;

FIG. 22 illustrates a top-perspective view illustrating a tool stationengaged with a tool base assembly of the automated tool change assemblyof the present invention;

FIG. 23 illustrates a side-perspective view of a tool station having atool base assembly and a wrist assembly engaging the tool base assemblyof the automated tool change assembly of the present invention;

FIG. 24 illustrates a side-perspective view of the tool station with thewrist tool exiting the tool station of the automated tool changeassembly of the present invention;

FIG. 25 is a block diagram illustrating the steps to connect a wristassembly to a tool base assembly using a tool station of the automatedtool change assembly of the present invention;

FIG. 26 is a block diagram illustrating exemplary steps to disconnect atool base assembly from a wrist assembly of the automated tool changeassembly of the present invention;

FIG. 27 is a block diagram illustrating information flow in a robotmanipulator of the automated tool change assembly of the presentinvention; and

FIG. 28 is a diagram illustrating a robot with a two-dimensional armutilizing the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The automated tool change assembly of the present invention providesfirst and second light-weight mechanical joint members for automatedcoupling. The automated tool change assembly provides a rigidconnection, for connecting an end effector to a robotic manipulator. Theautomated tool change assembly can include an electrical connection topass power and signals between the end effector and the manipulator. Theconnection can also have full pass-through mechanical power. Endeffectors for attaching using the automated tool change assembly caninclude components such as a retrievable delivery device, gamble grip,dozer, shovel, tilting tools, plow, drills, saws, cutters, grinders,sensors, camera, disrupter, arm extenders, arm linkages, digging tolls,and pan-tilt table. One skilled in the art will recognize this list isnot exhaustive and the use of other types of robot components with theautomated tool change assembly of the present invention is possible.

A further object of the present invention is adaptability. End effectorscan operate seamlessly as the automated tool change assembly provideselectrical connectors for transmitting signals between controllers andprocessors, since they can be plug-n-play. In one embodiment, anoperator control unit can identify a current end effector and currentcontroller by reading an embedded chip jumper, or resistor in the endeffector and can pass electrical signals to control the end effectorthrough the automated tool change assembly of the present invention. Theembedded chip can obtain a unique identifier for that particular endeffector. Therefore, when a new end effector is attached using theautomated tool change assembly of the present invention, a uniqueidentifier for the tool can be read and passed to an onboard or externalcomputer system that can analyze the signal to identify the present endeffector. The operator control unit can transmit messages to theprocessor on the arm or to operate the end effector accordingly.

With reference to FIG. 1a , a first joint member, tool base assembly 2and second joint member, wrist assembly 4 are shown with the tool baseassembly 2 positioned to engage with the wrist assembly 4. The tool baseassembly 2 can have a lock ring 6, electrical connector 8, and aconductor plate 10. Tool base assembly 2 can be mounted to a number ofdifferent end effectors. The wrist assembly 4 can have a lock plate 12,a follower ring 14, and an electrical receiver 16. The wrist assembly 4forms a cylindrical body having a cavity 18 in the middle for receivinga tool base assembly 2. When the tool base assembly 2 is displaced intothe wrist assembly 4, a connection can be made between them. Theinteraction of the parts of tool base assembly 2 and wrist assembly 4 isdiscussed in detail below.

With reference to FIG. 1b , a robot arm shows the degrees of freedomthat the arm provides. Wrist assembly 4 can be mounted to the end of afour degree freedom arm, which includes yaw, boom, and stick motion, aswell as wrist rotation, which is concentric to the axis of the assembly.

With reference to FIG. 2a , in addition to lock ring 6 and electricalconnector 8, a tool base assembly 2 can also have a connector plate 32and lower engagement members, track pins 36 a, 36 b and upper engagementmembers, track pins 37 a-37 d.

With reference to FIG. 2b , an exploded view of the tool base assembly 2and its member parts including lock ring 6, electrical connector 8, andconductor plate 10 can have conductor pin 20 a and a short conductor pin20 b. These pins 20 a, 20 b are positioned in cavities 22 a, 22 b formedabout the surface of the electrical connector 8. The conductor pins 20a, 20 b can be mounted on the conductor plate 10 with pins 24 a, 24 bconnecting with the conductor pins 20 a, 20 b through holes 26 a, 26 bof the conductor plate 10.

With continuing reference to FIG. 2, tool base assembly 2 can furtherhave a cylindrical body, electrical casing 28 coupled to the conductorplate 10 using screws (not shown) inserted into holes 30 a-30 d.Electrical casing 28 can be connected to a connector plate 32. Connectorplate 32 has a cavity therethrough and screw holes 38 a-38 d forcoupling with electrical casing 28. Connector plate 32 has a set ofholes 34 a-34 d for attaching lower track pins 36 a, 36 b, and upper 37a, 37 b into them. Lower track pins 36 a-36 b and upper track pins 37a-37 b can have threaded heads or attached using other fastener methodsknown in the art. When fastened to connector plate 32, the pin bodyremains external from the holes for coupling with a tool station 400, asdescribed hereinafter. The plate 32 can be coupled to a box 44 withholes 40 for receiving threaded members (not shown) into holes 46 of box44. Box 44 can hold a microcontroller 42. Microcontroller 42 can storeprogramming instructions and transmit and receive electric signals toother processors or drives to activate control of the end effector thatis being used on tool base assembly 2.

With reference to FIG. 3, an exploded view of the wrist assembly 4 andits member parts including the lock plate 12, follower ring 14, andelectrical receiver 16 is shown. As shown in FIG. 1, wrist assembly 4can have a continuous cavity 18 running the length of wrist assembly 4and passing through each member of wrist assembly 4. Wrist assembly 4can have a body, lock hub 52. Lock hub 52 fastened to lock plate 12 andholding follower ring 14. Lock hub 52 can have a cylindrical shape witha set of legs 54 a-54 d circumferentially placed, extending axiallyinward and intertwined with carrier plate 56. The carrier plate 56 canhave tabs 90 a circumferentially spaced and extending radially outward.Each tab 90 a having a set of respective holes 59 a-59 d and 94. Holes59 a-59 d are for holding pins 58 a-58 d. Holes 94 are for coupling to alock collar 60. Lock collar 60, a cylindrical body having a set of tabs92 positioned circumferentially and radially facing inward on the insideof the lock collar 60 can fasten to corresponding tabs 90 a of thecarrier plate 56. Legs 54 a-54 d of lock hub 52 can pass throughcavities formed between the connector of collar 60 and the carrier plate56. The carrier plate can have lock member fastened thereto, forexample, a set of lock pins 58 a-58 d mounted to carrier plate 56. Thepins 58 a-58 d can engage holes 57 of the lock hub 52 and coincidingholes of lock ring 6, lock plate 12, and follower ring 14, as describedbelow.

With continued reference to FIG. 3, electrical receiver 16 can haveconductor pins 62 a, 62 b inserted into slotted surfaces 64 a, 64 bformed on an internal wall of electrical receiver 16. The pins 62 a, 62b can be held in place by a conductor plate 66 having holes 68 a, 68 bthrough which a pin 70 can pass and further insert into an axial hole(not shown) in the bottom of conductor pin 62 a, 62 b, giving it supportand holding it in position. One skilled in the art will recognize anynumber of conductor pins can be used in the housing depending on thetype of electrical connections needed.

A cylindrical grooved housing 72 can be coupled to the conductor plate66 holding a motor 74 for passing mechanical power can be coupledthereto and held in position by a plate 82 jointly coupled to housing 72and motor 74. Housing 72 can provide a mechanical power take off (PTO)self-aligning drive shaft at least partially inside. The PTO can have adriveshaft 76, a compression spring 78, and a drive hub 80 and isdescribed in detail hereinafter. Plate 82 can hold the PTO from movingand it is connected to the housing 72. Holes 84 a-84 d of plate 82 canreceive threaded members (not shown) to fasten plate 82 to housing 72.Holes 86 a-86 d of housing 72 can receive threaded members passingthrough holes 88 a-88 d of conductor plate 66 and into holes (not shown)on locking collar 60. Members 96 fasten the lock plate 12 to lock hub52. One of skill in the art will recognize that threaded members caninclude screws, pins, or other fasteners.

In FIG. 4a , the lock ring 6 and lock plate 12 are shown aligned readyfor engagement. The lock ring 6 can have tabs 120 a-120 d. The tabs 120a-120 d can form a clover leaf configuration. In one embodiment, one ofthe tabs, tab 120 c can define a key tab having a slightly larger sizethan tabs 120 a, 120 b, 120 d. The tabs 120 a-120 d define notches 122.The tabs 120 a-120 d corresponds to tabs 100 a-100 d of lock plate 12.The lock ring 6 further includes holes 124 a-124 d, 126 a-126 d. Thetabs 120 a-120 d of lock ring 6 can have chamfered edges 128. The lockplate 12 can have tabs 100 a-100 d, also defining notches 102 a-102 dbetween the tabs 100 a-100 d. The tabs 100 a-100 d can have a hole 104a-104 d therethrough. The lock plate 12 can also have chamfered surfaces108 about the rim of the tabs 120 a-120 d and notches 102 a-102 d. Thechamfered surfaces 108 and 128 can facilitate the mating of lock ring 6and lock plate 12. When mating, key tab 120 c ensures the tabs 120 a-120d of the lock ring 6 only mate with tabs 100 a-100 d of lock plate 12 inone position, ensuring the tool base assembly 2 is aligned properly withthe wrist assembly 4 for displacement into the wrist assembly 4.

With reference to FIG. 4b , displacing lock ring 6 axially into the lockplate 12 positions the tabs 120 a-120 d within the notches 102 a-102 dformed by tabs 100 a-100 d of lock plate 12. The key tab 102 c can havea special size or shape where it is only fitting into the key notch 102c of lock plate 12.

With reference to FIG. 5a , the tool base assembly 2, after alignment,can be displaced into the wrist assembly 4. The wrist assembly 4 limitsthe amount of displacement of the tool base assembly 2 as the electricalreceiver 16 mates with electrical connector 8 and the axial movement ofthe tool base assembly 2 into wrist assembly 4 is stopped. After axialmovement of tool base assembly 2 is stopped, rear surface 130 of lockring 6 is inside lock plate 12 of the wrist assembly 4.

With reference to FIG. 5b , the lock ring 6 is positioned inside of thelock plate 12 and no further axial movement of tool base assembly 2 cantake place.

With reference to FIG. 6, when the automated tool change assembly isfully engaged with the lock ring 6 as the tool base assembly 2 isrotated, the tabs 120 a-120 d of the lock ring 6 are rotated and forcedunderneath the tabs 100 a-100 d of lock plate 12. Rotational force onthe lock ring 6 also causes the rotation of the follower ring 14, movingthe tabs on the follower ring 14 to coincide with the notches 102 a-102d of the lock plate 12.

With reference to FIG. 7, when the lock plate 12 and lock ring 6, alignholes 104 a-104 d of lock plate 12 align and with the respective holes124 a-124 d of lock ring 6. With reference to FIG. 8, the position oflock ring 6 is inside lock plate 12.

With reference to FIG. 9a , when lock ring 6 and the lock plate 12 arealigned, pins 58 a-58 d of carrier plate 56 are free to move into theholes 104 a-104 d of the lock plate 12 and the holes 124 a-124 d of lockring 6. With reference to FIG. 9b , springs 180 can be positionedbetween the plate 66 and lock collar 60. The pins 58 a-58 d of carrierplate 56 have an axial force placed on them by springs 180 in thelocking collar 60, causing the pins 58 a-58 d to move into the holes 104a-104 d and 124 a-124 d when the lock plate 12 and lock ring 6 arerotated into complete alignment relative to each other. The wristassembly 4 and the tool base assembly 2 lock when the pins move into theholes, locking three translational degrees of freedom and two of therotational degrees of freedom between the wrist assembly 4 and the toolbase assembly 2. The lock ring 6 includes a chamfered surface 134 on theinside of the holes. A conical shoulder 132 of the pins 58 a-58 d willrest against surface 134 when fully engaged as described hereinafter.

With reference to FIG. 10, when the tool base assembly 2 and the wristassembly 4 are rotated into the alignment position, the lock pins 58a-58 d and the carrier plate 56 slide axially toward the holes 102 a-102d, 124 a-124 d to create a double-shear pin joint in the four locationswhere the holes 102 a-102 d, 124 a-124 d are aligned. Lock pins 58 a-58d can be slightly rounded, tapered, or sloped on the leading edge toprovide a self-guided action to tolerate misalignment between the wristassembly 4 and the tool base assembly 2.

With reference to FIG. 11, when lock ring 6 is engaged with lock plate12, pins 58 a-58 d mate with holes 57 of lock hub 52. In addition, thepins 58 a-58 d can have a smaller diameter than the holes 120 a-120 d oflock ring 6 and holes 102 a-102 d of the lock plate 12. This smallerdiameter is utilized for tolerating debris as well as manufacturingvariations. The conical shoulder 132 of pins 58 a-58 d wedges againstchamfered surface 134 of the lock ring 6. Locking collar springs applyaxial force on the conical shoulder 132 of pins 58 a-58 d, pushing theshoulder 132 into the chamfered surface 134, allowing friction andspring force to provide sufficient force to keep pins from popping outwhen side force occurs. The angular slope of the conical pin is steepenough that side force will not pop out the pin and not so steep that itself locks, in one embodiment defining a 45° angle. This movementprovides a self-centering of the pins 58 a-58 d in the hole 124 a-124 d,aligning the lock ring 6 and removing backlash between the tool baseassembly 2 and the wrist assembly 4. Component parts of the automatedtool change assembly are manufactured to tolerate debris andmanufacturing variations. As the automated tool change assembly isdesigned to form connections between loose fitting parts, the taperedengagement of each lock pin 58 a-58 d leaves clearance for debris.

With reference to FIG. 12, the lock ring 6 can have chamfered surfaces128 to ease a chamfered surface 136 a-136 d. Similarly, lock plate 12can have chamfered surfaces 108. Chamfered surface 136 of lock ring 6coincide with chamfered surfaces 138 a-138 d of lock plate 12 andfacilitate mating of the surfaces as the tool base assembly 2 isdisplaced into the wrist assembly 4. The chamfered edged surfaces 136a-136 d and chamfered surfaces 138 a-138 d meet and help the lock ring 6slide past the lock plate 12. Additional chamfered surfaces can ease therotational resistance when the lock ring 6 and lock plate 12 are rotatedagainst each other, causing the lock ring 6 to slide under the lockplate 12.

With reference to FIG. 13a , the lock ring 6 is shown aligned withfollower ring 14 of wrist assembly 4. The follower ring 14 can havemembers tab 140 a-140 d forming notched surfaces 142 a-142 d having adetent 144 a-144 d therein. The detent 144 of follower ring 14 can havea ball detent assembly which keeps the follower ring 14 in thedisengaged position until a tool is inserted. A member (not shown), suchas a ball or tab can be formed on the lock hub 52 for mating with thedetents 144 a-144 d.

With reference to FIG. 13b , wrist assembly 4 is shown unengaged. Withreference to FIG. 13c , a cross section of follower ring 14 of wristassembly 4 a long lines A-A of FIG. 13b , showing a slot 152 formed infollower ring 14 for mating with a member, pin 150 fastened to lock hub52. The combination of pin 150 with slot 152 can limit the rotation offollower ring 14 during engagement and thereby limit the rotation of thewrist assembly 4 counter to the tool base 4. For example, rotation canbe limited to 45° in an embodiment having four tabs on lock ring 6 oftool base 2. Other embodiments are envisioned having a different numberof tabs on the lock ring 6, lock plate 12, and follower ring 14 where adifferent rotational angle is needed, slot 152 can provide such anangle.

With reference to FIG. 14a , the follower ring 14 is in the openposition and the lock ring 6 has been displaced into the follower ring14. In the open position, the lock pins 58 a-58 d of the locking collar14 is prevented from sliding into the locked position (see FIG. 12).This prevents the locking collar 60 from opening, especially when notool base assembly 2 is inserted. By blocking the pins 58 a-58 d, thelocking collar 60 also remains open, the springs having a potential tomove the collar 60 when open. The user of the automated tool changeassembly can move the follower ring 14 by placing the tool base assembly2 into the wrist assembly 4 and rotate it until the locking collar 60slides into the locked position.

With reference to FIG. 14b , when the lock pins 58 a-58 d are pressingagainst the closed follower ring 14, the pins 58 a-58 d are preventedfrom moving into the engagement position.

With reference to FIG. 14c , when the lock ring 6 has been rotated, itcauses the rotation of the follower ring 14 into the closed position. Inthe closed position, the pins 58 a-58 d are freed to move through holes144 a-144 d of follower ring 14. The follower ring 14 can limit therotation of the tool to a 45 degree rotation required to engage anddisengage the tool base assembly 2 from the wrist assembly 4. This keepsthe keying assembly aligned within the wrist assembly 4.

With reference to FIG. 15a , a conductor pin mounting assembly can havea conductor block 200 having holes for receiving conductor pins placedabout the conductor block 200. A hole 201 can receive a conductor pin212 having a cross hole 214. On the back 210 of the conductor block 200,hole 201 can include a slot 202. An end of conductor pin 212 havingcross hole 214 extends from the back 210 of conductor block 200. Crosshole 214 receives a roll pin 206, which is seated in the slot 202 ofhole 201. The roll pin 206 mates with the slot 202 of hole 201. Afiberglass plate 208 can be inserted on top of conductor block 200 oncethe roll pins 204 have been fastened. The fiberglass plate 208 is aninsulating plate that is bolted in place over the roll pins 204,maintaining the roll pins 204 position. The rotational position of theroll pins 204 is aligned and the roll bar 206 acts as a pin joint toallow the roll pins 204 to pivot about the axis of the roll pins 204.This method is also useful for quick disassembly.

Returning to FIG. 15a , the conductor pin 212 further includes anelastic member 216 placed between the surface of the conductor block 500and the conductor pin 212. The elastic member 216 provides forcedirected toward the center axis of the wrist assembly 4 to press thecontacts together upon the tool base assembly 2 displaced into the wristassembly 4. The elastic member 216 also provides compliance, allowingthe pin 212 to partially rotate about the axis. During engagement, therotation of pin 212 in connection with the electrical receiver atcondition 510 of tool base assembly 2 causes contact surface 218 to comein contact with a contact surface of a corresponding pin.

With reference to FIG. 16, the electrical receiver conductor block 200can mate with an electrical connector conductor block 230. Conductor pin212 of conductor block 200 can have contact surface 218 and elasticmember 216 engaged between the rear surface. The contact surface 218 ofpin 212 is shown having a detent 222 forming a first contact point 224and a second contact point 226 when rotated, sweep against a conductorpin 220 of the connector 218. A conductor pin 220 of conductor block 230contacts the detent surface 222 of conductor pin 220 forming electricalcontacts at two points 224, 226 due to the detent 226 of pin 212. Whenpin 220 of the tool base assembly 2 comes into contact with the pin 212of wrist assembly 4 during a rotary motion, the pins 220, 212 provide awiping action against each other to clean and dislodge debris. Theopposing pins provide counter forces, therefore, the contact system doesnot contribute any tool insertion force and the load path is containedwithin the conductor block 200, so the arm only needs to provide a smalltorque to rotate the contacts into engagement. The elastic member 216provides resistance to force and provides compliance against vibration,electrical noise, and low tolerances.

With reference to FIG. 17a , a mechanical power take off (PTO)self-aligning drive 300 can have drive shaft 76, compression spring 78,and drive hub 80 positioned in the wrist assembly 4. A coupler 310 canbe positioned in the tool base assembly 2. PTO 300 can be used tomechanically couple driven tools connected using the automated toolchange assembly with a motor residing within the wrist assembly 4. Thedrive shaft 76 is coupled to the output of a motor using a slip fit boreand a set screw or other clamping method known in the art. The driveshaft 76 can have a stepped pilot shaft 302 with a stepped portion 304and a cross hole (not shown). The drive hub 80 can have a cylindricalbore 305 a having a stepped surface 305 b and a slotted face 306 with avent 308 to prevent build up of a vacuum. The drive hub 80 can receivethe compression spring 78 and stepped pilot shaft 302 of drive shaft 76within the bore 305 a.

With reference to FIG. 17b , a dowel pin 312 is inserted through crosshole 314 of drive hub 80 and a cross hole (not shown) in drive shaft 76holding the shaft 76 and spring 78 within the hub 80. Five degrees offreedom are constrained by the dowel pin 312. The only free degree offreedom is translation freedom along the axis of the drive shaft 76. Thetranslation freedom is only limited by the length of the cross hole 314as the dowel pin 312 moves therein. The dowel pin 312 transfers torqueabout the axis of the drive shaft 76 and slides along the slot 314 ofhub 80 to provide axial compliance. The compression spring 78 iscaptured in-between the drive shaft 76 and the drive hub 80 to providean axial force toward the tool base assembly 2. The axial force providesan engagement force to engage the hub 80 to coupler 310, having aslotted face 306 which mates with a slotted surface 306 of the drive hub80. The slotted head 316 of coupler 310 mates with slotted face 306 ofdrive hub 80. The coupler 310 can mate with an end effector connected totool base assembly 2. The coupler 310 provides a self-alignment, whichcan prevent binding during manual and automated tool change.

With reference to FIG. 17b , coupler 310 is shown in the disengagedposition. As it is rotated, the slotted head 316 of coupler 310 isinserted into a slotted face 306 of hub 80, it becomes engaged as shownin FIG. 17c . The movement of dowel pin 312 within cross hole 314 is dueto the spring force acting on hub 80 causing axial movement intoengagement with coupler 310. One skilled in the art would recognize thatother mechanisms to transfer torque between the drive shaft and drivehub could be used.

With reference to FIG. 18, the automated tool change assembly furtherincludes a tool station 400. The tool station serves the function ofholding the tools when not in use by an arm. In addition, tool station400 can provide correct positioning for tool base assembly 2 duringengagement. The tool station 400 can also interact with the wrist/toolassembly for disengagement. The tool station 400 can have legs 402, arms404, and lock ramp 406. The tool station 400 can be mounted on thesurface of a robot in a space relative to the arm. The mount can providerotational adjustment to allow the center plane of the tool station 400to align with the wrist assembly 4 from the top. One tool station 400 isused for each tool base assembly 2 on a robot. Any number of toolstations 400 can be used on a robot, depending on the space available onthe robot.

With reference to FIG. 19, the tool station 400 can have legs 408 a, 408b having holes 412 a, 412 b and 414 a, 414 b, respectively. A block 410is provided for mounting to a surface, such as a robot unmanned vehicle.A bore 411 of block 410 can receive a fastener for fastening to asurface, holes 416 a, 416 b, 418 a, 418 b of block 410 can be coupled toholes 412 a-412 b and 414 a-414 b of 408 a, 408 b with a fastener, suchas a screw or pin. Legs 408 a, 408 b can have an arched top 420 a, 420b, arched adjuster holes 422 a-422 b, and arched adjuster holes 424a-424 b, and a further hole 426 a therethrough. This adjustment providescapability to align the tool base assembly 2 axis to the axis of thewrist assembly 4 from the side. The holes 422 a-422 b, 424 a-424 b 426a-426 b can be used to fasten legs 402 to arm member 404, as shown inFIG. 18. Tool station 400 can have arms 430 a, 430 b, having holes 432a-432 b, 434 a-434 b for connecting arms 430 a-430 b with the adjusterholes 422 a-422 b, 424 a-424 b, and holes 426 a-426 b of legs 408 a and408 b. The screws can be used to adjust the angular position of the arm404 about the axis formed by holes 426 a-426 b. Arm 430 a-430 b canfurther have a two-stage track 436 a-436 b (not shown). 436 a-436 b hasramped surfaces 438 a-438 b, 440 a-440 b, ramps 438 a-438 b formed on anouter surface of ramps 440 a-440 b. The ramped surfaces 438 a-438 b actas ramps with respect to pins 36 a-36 b and 37 a-37 b of tool baseassembly 2 (see FIG. 2), guiding the tool base assembly 2 intoengagement with the tool station 400 as the arm 404 lowers the tool baseassembly 2 into the tool station 400. The shortened length of ramps 438a-438 b delays the engagement of the upper pins 37 a-37 b of tool baseassembly 2. The upper pins 37 a-37 b can also have a shorter length,thereby not engaging with ramps 440 a-440 b. Guides 442 a-442 b providefor lateral compliance of the lower pins 36 a-36 b with the tool station400. Block 444 includes holes 446 a-446 b, 447 a-447 b, 448 a-448 bholding the arms 430 a-430 b together.

With continuing reference to FIG. 19, plates 454 a-454 b are providedhaving a striker 458 a (not shown) and 458 b positioned on an internalsurface extending outward having a ramped surface 459 on one sidethereof. The plates 454 a-454 b can be attached by a hollow cylindricalbar 461 coupled to holes 461 a-461 b. The plates 454 a-454 b can alsohave a manual release 460 attached with holes 462 a-462 b and 464 a-464b to holes 463 a-463 b, respectively. Holes 466 a-466 b and 468 a-468 bare provided for fastening plates 454 a-454 b to the arms 404.

With reference to FIG. 20, the alignment ramps 438 a-438 b and 440 a-440b can provide an opening leading to the two-stage track 436 a-436 b,guiding engagement pins 36 a-36 b and 37 a-37 b. The degree of freedomof the engagement pins 36 a-36 and 37 a-37 b is restricted afterentering the ramps. Movement of the lower pins 36 a-36 b along track 436provides precise guidance of the tool base assembly 2 relating to thetool station 400 regardless of what the wrist assembly 4 is doing. Theramp guides the lower engagement pins 36 a-36 b during stages 1-4 ofengagement. The full length of two-stage tracks 436 a-436 b, and as itdoes, rotational freedom of the tool base assembly 2 about the axis ofthe lower pins 36 a-36 b provides compliance with height and locationparameters of the wrist assembly 4 during engagement. The rotationalfreedom is unrestricted during movement of the lower pins 36 a-36 b downthe track 436 a-436 b during 95% of the movement. Further movement ofthe tool base assembly 2 into the tool station 400 provides connectionof the second upper set of engagement pins 37 c-37 d with the secondalignment ramp 438. The second alignment ramp 438 b guides the upperpins 37 c-37 d during engagement steps 1-4 into a shortened outer trackof the two-stage track 436, eliminating rotation freedom of the toolbase assembly 2. As the lower pins 36 a-36 b enter and move down thetrack 436 during stages 1-3 of engagement, they meet the striker 458,causing the striker 458 to resist the pins 36 a-36 b during stage 3 ofengagement. As the lower pins 36 a-36 b continues from stage 3 ofengagement, they move the striker 458 downward against spring forcetransferred from manual release bar 460 to a member 462 of lock ramp406. When the pins 36 a-36 b are clear, the spring force causes thestriker 458 to return to the closed position at stage 4 of engagement.

With reference to FIG. 21a , the pin 36 a-36 b can move over the striker458. When pins 36 a-36 b are positioned over the striker 458, thestriker 458 is lowered to its original position. Pin 37 a is stillrotationally free. With reference to FIG. 21b , the striker 458 iscompletely open to allow the pins 36 a-36 b to pass. Pin 37 a is notrestricted rotationally.

With reference to FIG. 21c , the pins 36 a-36 d are locked behind thestriker 458 when the striker 458 returns to its initial position and theupper pin 37 a-37 b are inside the track 436.

With reference to FIG. 22, a handle on the side, bar 460 provides manualoperation for an operator to open the lock ramps and remove the toolbase assembly 2 from the tool station 400.

With reference to FIG. 23, plate 454 is shown adjacent the wristassembly 4. The plate 454 of lock ramp 406 can have a face 470, whichcan be aligned such that the wrist assembly 4 can rotationally engagetool base assembly 2. The axial force from the lock collar 60 moves thelock ramps 406 into the open position during the automated tool pick,thereby opening the striker 458.

With reference to FIG. 24, during parking of a tool, a slanted face 472,of lock ramp 406, can have a slope automatically providing thepenultimate step in the disengagement process to slide back the lockcollar 60, thereby releasing the pins 58 a-58 d of the wrist assembly 4as it is moved into place to park a tool base assembly 2 into the toolstation 400. Parking also moves the locking ramps 406 into the openposition as the force of the locking collar 60 pushes on the lock ramp406. To completely disengage, a final rotation of the wrist assembly 4counter to tool base assembly 2 can be given. When the wrist assembly 4is removed, the striker 458 is free to close, locking the tool baseassembly 2 to the tool station 400.

With reference to FIG. 25, a method of connecting a wrist assembly 4with a tool base assembly 2 begins at block 500 by providing a wristassembly 4 and tool base assembly 2. The tool base assembly 2 can beengaged with a tool station 400, as shown in FIG. 22. At step 502, thewrist assembly 4 is prepared by displacing it toward the tool baseassembly 2. In one embodiment, approximately one inch away. When thewrist assembly 4 is positioned proximate to the tool base assembly 2, asshown in FIG. 1, the wrist assembly 4 can be displaced axially into thetool base assembly 2 at block 508. While the wrist assembly is beingdisplaced toward the tool base assembly 2, at condition 510, thiscontinues until a full engagement depth has been reached. When fullengagement depth has been reached, the wrist assembly 4 has engaged toolbase assembly 2 and the tool base assembly 2 will have a lock ring 6inside of the wrist assembly 4, as shown in FIG. 5a . At block 514, toolbase assembly 2 is rotated relative to the wrist assembly 4. As thelocking ring 6 of the tool base assembly 2 rotates at block 514, thelocking ring 6 applies a rotational force on the follower ring at block520. At block 522, the electrical pins of the electrical connector 8 andelectrical receiver 16 create a sweeping motion, thereby cleaningcontacts of debris and moving into contact at block 522. At block 224,the locking collar 60 is released. The locking ring 6 has moved thefollower ring 14 rotationally opening a passageway to aligned holes ofthe locking ring 6, locking plate 12, and the lock hub 52, as shown inFIG. 9. Once rotation is completed at block 514, engagement holes of thelocking ring 6 and locking plate 12 are aligned at block 526. At block528, the locking collar spring forces axial displacement of the pins 58a-58 d into aligned holes of the lock ring 6, lock plate 12, and lockhub 52. Engaging the drive shaft 76 at block 530, the PTO coupler 310forms a mechanical power pass thru. The contact surfaces of theconductor 218, 220 are engaged at block 532, as shown in FIG. 16. Atblock 534, a communication signal can be transmitted from the onboardmicroprocessor of the tool base assembly 2 to the processor of the arms404 or further down to a computer processor housed on the robot. Atblock 536, the wrist assembly 4 and tool base assembly 2 are moved offof the tool station track 436. At block 538, the wrist assembly 4 andtool base assembly 2 disengages with the tool station 400.

With reference to FIG. 26, a method of disconnecting a tool baseassembly 2 from a wrist assembly 4 includes either a manual method or amethod automatically using the tool station 400. The disconnectionbegins at block 600 with a connected tool base assembly 2 and wristassembly 4. The wrist assembly 4 and tool base assembly 2 are positionedadjacent to a holder at block 602, as shown in FIG. 24. Next, the toolstation 400 is aligned rotationally and the tilt is adjusted to receivethe wrist assembly 4 at block 604.

With reference to FIG. 28, the robot 160 can have a two degree freedomarm 162. The tool station 400 provides flexibility to line the arm 162up with the automated tool change assembly 164 by positioning thehorizontal plane of the tool station assembly 400 in the horizontalplane of the arm 162. For alignment of the tool, when the tool station400 is positioned around robot 160, the lateral center plane of thewrist plane can be positioned coincident with the center plane of thetool station 400 by rotating the legs of the tool station 400appropriately.

With continuing reference to, block 604 can be done before beginning themethod to provide proper station configuration. At block 606, the wristassembly 4 is driven electronically (or manual placement) onto the toolstation 400. This movement causes the slanted face 472 to contact thelocking collar 60. Moving the locking collar 60 onto slanted face 472when collar 60 is locked, forces the collar 60 to open, causing the pins58 a-58 d of the locking collar 60 to move out of lock ring 6 and lockplate 12. At block 610, pins of the tool base assembly 2 slide into thealignment ramps 310. At block 612, the alignment ramps 310 guide thepins into the two-stage track 436, as shown in FIGS. 21a-21c . The lowerpins move along the track 436 at block 614. At block 616, rotationalfreedom about the axis of pins 36 a-36 b facilitates placement of thetool on tool station 400. Contacting the striker 458, pins 36 a-36 bcause the striker to open, allowing the pins to enter further track 436at block 618, moving the upper pins 320 further onto the ramp, placesthe lower pins in a position adjacent the lock ramps, guiding them intothe track 436. At block 622, when the pins 37 a-37 b have entered thetrack 436, all degrees of freedom is restricted. Pins 58 a-58 d isfinally free of the tool base assembly 2. With release of pins 58 a-58d, the wrist assembly 4 can be rotated, automatically or manually. Thewrist assembly 4 is rotated automatically using a motor inside the wristassembly 4 at block 626. In one embodiment, the wrist assembly 4 rotates45 degrees to open. At block 628, the locking collar 60 is blocked byfollower ring 14. At block 630, the striker 458 is closed, locking thetool base assembly 2 into place, as shown in FIG. 21c . At block 632,the wrist assembly 4 is disconnected, as shown in FIG. 22.

The automated tool change assembly can be connected and disconnectedusing programmed scripts processed by a computer processor on a robotcomputer and transmitted to drives throughout the arm, wrist, and caninclude the end effector.

A CanBus can provide communication channels between the operationcontrol unit OCV, arm, and end effector to transmit in addition tosupplying power signals. The signals can be messages that instructdrives that control components. The automated electronics need one drivefor each motor and can have the motor driver in an arm or an endeffector. The motors can be smart motors, monitoring details regardingbehavior of each tool. Controllers can quickly configure the drivesbased on feedback. The motor can have sensors to feed back to the driveinformation about what it's doing. The CanBus supplies the power and theelectrical connections and can limit the supply of power or can be toldto limit the supply of power to accommodate the motor sensors. The powersupply can be a 48 volt vehicle battery, however, this is not a limitingfeature of the invention, supplying 20 amps to the arm. However, oneskilled in the art will recognize other electrical supplies can replacethe battery.

With reference to FIG. 27, an arm 100 receives information sentthroughout the manipulator from operator control unit 702 using JointArchitecture for Unmanned Systems (JAUS) to transmit a message 704. Themotor controller can be coupled to an arm or alternatively, can bepositioned closer to the end effector and can receive power through theCanBus. The motor controller can control a motor, and alternatively, cancontrol the brakes on the motor. The motor controller can act like anamplifier.

Program code can provide instructions to the components to complete anaction. Using motor currents, a processor can determine proper actionsbased on conditional logic within a program. Program code can also beused to control processors to cross check absolute sensors in motors.When behavior is outside a range, steps can be repeated until the properrange is reached. Scripts can provide a series of predetermined stepsoperating the arm and end effector. A microprocessor, sensors, and anonboard computer chip can be used to move end effectors to a specificposition. Error messages can be sent to the operator as they occur.

With continued reference to FIG. 27, the arm computer 706 receives theinstructions from the OCU 702. A translator 712 translates theinstructions, doing computation 710 to determine position and velocityof joints having an arm. Each joint may possibly have its own ebox.Next, the arm computer 706 sends to the translator 712 program code totranslate instructions for sending to components over the CanBus, USB,or serial connection. Each CAN translated instruction provides a message719 for identifying an outcome parameter in a grid 716, such as amovement of an arm or torque of a motor. The instructions can be used tocontrol motor drive 712 or tool computer 720. Tool computer 720transmits to a tool, such as gripper 722 and also is capable to read thetool ID Board.

With continuing reference to FIG. 27, operation control unit 702 canhave an attach tool button for attaching a tool, such as a gripper tothe robotic manipulator. When a user presses the attach tool button, amessage 704 is sent to the arm 706 and is translated at the translator708. The message 704 can trigger a series of steps to attach a tool. Inthe script, the first step is to move the arm of the robot to a safealtitude and joint space. This involves moving the arm straight up untilthe arm is high enough for safe clearance. Next, the arm is positionednear the tool station that is used to hold the tools a safe positionaway from the robot deck. A database 724 can be searched by thecomputation module 710 to acquire the station ID the tool stationholding the gripper, or if another tool is being used, it would searchfor the station ID for that tool. After the computation module locatesthe station ID, it determines a calibration point, the point used forall measurements, by looking up in the database using the station ID.Next, the computation 710 determines the important points based on thecalibration point. The arm can then move to a pre-engaged point in jointspace near the station. The wrist can be twisted to a pre-engage angle,for example, approximately 45°. Actions are accomplished by sendingmessages via translator 712 to the different motor drives 718 and toolcomputers 720, attached to the tools, such as gripper 722. Motor currentcan be limited causing the engagement force to be less than full force.The arm is driven in Cartesian mode along the engagement vector. The armcontinues to be driven along the vector until the tool is connected.Additionally, if a time limit or a final position is not reached, thearm movement can be stopped because the time and/or position indicateerror. The scripts can also use motor current and position informationreceived from drives. If motor current is exceeded, or if a positionerror is determined within a range, arm movement can be stopped. Afterthe arm is connected, the wrist is twisted to what is an over-engagedangle. The arm computer can determine that the wrist is engaged if thetool ID boot-up is accomplished. In addition, the angle of engagementcan be tracked. If the motor current exceeds a limit, for compliance,the wrist is stopped from twisting. When the software detects and knowsthat the tool has been attached, the wrist is twisted back to engagementangle, therefore it is twisted to center the wrist. The arm computer 706calculates angles to determine the proper position of the engagement.The arm is driven to a post-engagement point in Cartesian mode after itis engaged by sliding up and out of the tool station. The collar willstart to snap down, causing the engagement pins to move into place. Thearm can then be driven to a safe point. Next, the OCU 702 of the armcomputer 706 can determine exactly which tool is engaged by checking thetool ID information to reconcile that the proper tool was loaded. Basedon the tool ID, the motors are configured and the variable current orany current is determined. The PTO motors are configured based on thetool ID and any motor drives on the tool are initialized. The station IDis stored in memory or a database in order to determine where to returnthe tool when the present job is completed. Finally, the toolinformation is sent to the OCU 702 so that the OCU can determine whichtool is attached to the manipulator. The OCU 702 can then initialize theoperation settings, which are screen controls, operator controllers, andjoy sticks for the new tool. At this point, the operator can control thenew tool by sending commands from the operator control unit to the armcomputer 706.

Additional procedures are available to perform other functions, such ascalibrating tool stations. The tool station can be calibrated by placinga tool in the station and then driving the arm to a calibration point. Asaved calibration point button can be programmed on the operator controlunit to save the actual calibration point that is determined. This stepsends a message to the arm computer 706 to store the current calibrationpoint in database 724. The station ID is also stored for the specificcalibration point and the next time that tool is needed, the computercan retrieve the information from the database.

These and other features and characteristics of the present invention,as well as the methods of operation and functions of the relatedelements of structures and the combination of parts and economies ofmanufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention. As usedin the specification and the claims, the singular form of “a”, “an”, and“the” include plural reference unless the context clearly dictatesotherwise.

The invention claimed is:
 1. An assembly for automatically connecting anend effector to a robotic arm comprising: a first joint membercomprising a locking ring, and a connection plate; and a second jointmember comprising a cylindrical body, a locking plate, a locking member,and a locking collar, said locking collar being coaxially aligned withand slidably coupled to said cylindrical body, a locking collar carrierplate including said locking member extending axially therefrom, saidsecond joint member including a spring providing axial force on saidlocking collar, such that said locking plate of said second joint memberengages said locking ring of said first joint member, said locking plateand said locking ring having at least one intervening circumferentiallyspaced tab engageable in keyed relationship, said tab including anengagement hole extending axially therethrough, such that axiallydisplacing said first joint member into said second joint memberpositions said first joint member locking ring inside said second jointmember locking plate, such that a counter rotation between said firstand second joint members slides said locking ring tab of said firstjoint member under said locking plate tab of said second joint member,aligning said engagement holes causing said spring force on said lockingcollar to push said locking member through said aligned engagement holesof said locking plate tab and said locking ring tab to connect saidfirst joint member to said second joint member.
 2. The assembly of claim1, further including a follower ring, said follower ring having a tabpositioned between said locking plate and said locking collar carrierplate such that said follower ring is preventing movement of saidlocking collar by preventing said locking member from entering saidengagement holes, said follower ring tab further engaging said lockingring to prevent rotation of said locking ring past an alignmentposition, such that said locking ring aligns with said locking plate ofsaid second joint member.
 3. The assembly of claim 1, wherein saidlocking ring and said locking plate further including a plurality oftabs engageable in keyed relationship, such that a key tab of saidlocking ring uniquely engages with an opening formed between two tabs ofsaid lock plate providing only one engagement orientation of saidlocking plate with said locking ring.
 4. The assembly of claim 1,further comprising: a gear motor, said gear motor housed in said secondjoint member; a self aligning shaft; and wherein said self aligningshaft transfers mechanical power from said gear motor of said secondjoint member.
 5. The assembly of claim 4, wherein said self aligningshaft further including: a coupler housed in said first joint memberhaving a slotted head; a drive shaft having a dowel pin, a compressionspring, and a drive hub housed in said second joint member, said drivehub having a slotted face, a cross slot and a stepped cylindrical bore,such that said drive shaft engages said cylindrical bore, such that saiddrive hub cross slot provides axial compliance, as translational freedomalong an axis of the drive shaft is limited by the length of said crossslot when said dowel pin interacts with said cross slot, such that saidcompression spring positioned inside said cylindrical bore and coupledto said drive shaft, provides axial force away outward from said driveshaft, such that upon rotational alignment, said coupler engages thedrive hub slotted face and a rotational torque is transferred from saiddrive shaft, through said drive hub to said coupler.
 6. The assembly ofclaim 5, wherein mating said dowel pin to said cross slot of said drivehub provides said rotational torque.
 7. The assembly of claim 1, whereinengagement of said locking member with said engagement holes of thelocking ring tab and the locking plate tab locks three translationaldegrees of freedom and three rotational degrees of freedom.
 8. Theassembly of claim 1, wherein said assembly further comprising: anelectrical connector located in said first joint member; and anelectrical receiver located in said second joint member, said receivercomprising: a pin holder and a pin having a contact surface, said pinholder for holding said pin in alignment for coupling said electricalreceiver pin contact surface to a contact surface of a pin in a pinholder of said electrical connector, such that a displacement positionssaid electrical connector aligned with electrical receiver, said counterrotation causing an electrical connection.
 9. The assembly of claim 8,wherein coupling said electrical receiver pin contact surface to saidelectrical connector pin contact surface comprises a rotary wipingmotion as the first joint member is rotatably connected to the secondjoint member, said rotary wiping motion for removing debris from saidelectrical contact surfaces.
 10. The assembly of claim 9, wherein saidelectrical receiver further comprises a flexible member resting in anotched wall of said pin holder adjacent said pin of said electricalreceiver, wherein said flexible member provides force directed toward acenter of the electrical receiver, said force pressing said contactsurfaces together during rotation of said first joint member withrespect to said second joint member.
 11. The assembly of claim 10,wherein said pin of said electrical receiver can pivot radially, suchthat said flexible member of electrical receiver further providescompliance or resistance to vibration.
 12. The assembly of claim 8,wherein said electrical receiver pin comprises a grooved contactsurface, said groove forming multiple contact lines when engaged withsaid pin of said electrical connector.
 13. The assembly of claim 1,wherein the locking member is a pin, a screw, or a fastener, comprisinga conical surface for mating a chamfered surface.
 14. The assembly ofclaim 1, comprising chamfered edges on a plurality of teeth of saidlocking ring and said locking plate, wherein rotation forces saidchamfered teeth of said locking ring to slide under said chamfered edgesof said locking plate teeth, such that said chamfered edges facilitateengagement of said teeth of said locking ring and plate.
 15. Theassembly of claim 1, wherein said first joint member and said secondjoint member are engaged to form an electrical connection operative totransmit images, control signals, activators, identificationinformation, video, USB, TCP/IP, UDP, and CanBus, feedback information.16. The assembly of claim 1, wherein said second joint member isconnected to a robot arm.